Inspection

INSPECTION

Camshaft





Measure cam height (longer diameter of the cam). If it exceeds the limit, replace the camshaft.
Standard value:
Intake side 37.58 mm (1.4795 inch)
Exhaust side 36.95 mm (1.4547 inch)
Limit:
Intake side 37.08 mm (1.4598 inch)
Exhaust side 36.45 mm (1.4350 inch)

Lash Adjusters





Caution:
1. The lash adjusters are precision-engineered mechanisms. Do not allow them to become contaminated by dirt or other foreign substances.
2. Do not attempt to disassemble the lash adjuster.
3. Use only fresh diesel fuel to clean the lash adjusters.

1. Prepare three containers and approximately five liters of diesel fuel. Into each container, pour enough diesel fuel to completely cover a lash adjuster when it is standing upright. Then, perform the following steps with each lash adjuster.





2. Place the lash adjuster in container A and clean its outside surface.

NOTE: Use a nylon brush if deposits are hard to remove.





3. Fit special tool MD998441 onto the lash adjuster.
4. While gently pushing down the internal steel ball using special tool MD998442, move the plunger through 5 to 10 strokes until it slides smoothly. In addition to eliminating stiffness in the plunger, this operation will remove dirty oil.

Caution: The steel ball spring is extremely weak, so the lash adjuster's functionality may be lost if the air bleed wire is pushed in hard.

NOTE: If the plunger remains stiff or the mechanism appears otherwise abnormal, replace the lash adjuster.





5. Remove the lash adjuster from the container. Then, push down the steel ball gently and push the plunger to eliminate diesel fuel from the pressure chamber.





6. Fit special tool MD998441 onto the lash adjuster.
7. Place the lash adjuster in container B. Then, gently push down the internal steel ball using special tool MD998442 and move the plunger through 5 to 10 strokes until it slides smoothly. This operation will clean the lash adjuster's pressure chamber.

Caution: The steel ball spring is extremely weak, so the lash adjuster's functionality may be lost if the air bleed wire is pushed in hard.





8. Remove the lash adjuster from the container. Then, push down the steel ball gently and push the plunger to eliminate diesel fuel from the pressure chamber.





9. Place the lash adjuster in container C. Then, gently push down the internal steel ball using special tool MD998442.

Caution: Do not use container C for cleaning. If cleaning is performed in container C, foreign matter could enter the pressure chamber when the chamber is filled with diesel fuel.





10. Stand the lash adjuster with its plunger at the top, then push the plunger downward firmly until it moves through its greatest possible stroke. Return the plunger slowly, then release the steel ball and allow the pressure chamber to fill with diesel fuel.
11. Remove special tool MD998441.





12. Remove the lash adjuster from the container, then stand the lash adjuster with its plunger at the top. Push the plunger firmly and check that it does not move. Also, check that the lash adjuster's height matches that of a new lash adjuster.

NOTE: If lash adjuster contracts, perform the operations (9) through (12) again to fill it with diesel fuel completely. Replace the lash adjuster if it still contracts after performing these steps.





13. Set the ash adjuster on the special tool MD998440 (leak down tester).
14. After the plunger has moved downward slightly [0.2 to 0.5 mm (0.008-0.019 inch], measure the time taken for it to move downward by a further 1 mm.
Standard value: 3-20 seconds/1 mm (0.04 inch) [with diesel fuel at 15 to 20°C (59-68°F)]

NOTE: Replace the lash adjuster if the time measurement is out of specification.





15. Fit special tool MD998441 onto the lash adjuster.
16. Place the lash adjuster in container C again, then gently push down the internal steel ball using special tool MD998442.
17. Stand the lash adjuster with its plunger at the top, then push the plunger downward firmly until it moves through its greatest possible stroke. Return the plunger slowly, then release the steel ball and allow the pressure chamber to fill with diesel fuel.
18. Remove special tool MD998441.





19. Remove the lash adjuster from the container, then stand the lash adjuster with its plunger at the top. Push the plunger firmly and check that it does not move. Also, check that the lash adjuster's height matches that of a new lash adjuster.

NOTE: If lash adjuster contracts, perform the operations (15) through (19) again to fill it with diesel fuel completely. Replace the lash adjuster if it still contracts after performing these steps.

20. Stand the lash adjuster upright to prevent diesel fuel spilling out. Do not allow the lash adjuster to become contaminated by dirt or other foreign matter. Fit the lash adjuster onto the engine as soon as possible.